Modulating burner

ABSTRACT

A burner includes a diffuser in which first openings and second openings are provided for the passage of a mixture of fuel and air delivered to the burner. A distributing element is arranged inside the burner near the diffuser and is provided with further first openings and further second openings for the passage of the mixture. An ionization sensor is arranged near a zone of the surface of the diffuser in a direction substantially parallel to the surface of the diffuser. The first openings are shaped as holes and the second openings are shaped as slits. Two rows of slits are provided in the zone. The rows are separated by a surface portion of the diffuser devoid of openings. The ionization sensor is arranged above the surface portion of the diffuser between the two rows of slits.

The present invention relates to a modulating burner, in particular to a modulating burner with which an ionization sensor is associated for monitoring the combustion of a mixture of air and fuel delivered to the burner.

The ionization sensors are in general associated with burners for controlling the presence of the flame and the quality of combustion.

It is known that the flame produced by the combustion of the mixture delivered to a burner causes ionisation of the burnt mixture in the zone immediately surrounding the flame.

The ionization sensor is arranged near the surface of the diffuser of the burner, so as to be located in the zone affected by the ionisation produced by the flame and to generate a signal that is proportional to the ionization in said zone.

In the diagramming set out below, the typical pattern of the signal S₀ produced by the ionization sensor in a prior-art burner is shown.

If the signal S₀ produced by the ionization sensor falls below a preset first value S_(min) or exceeds a preset second value S_(max), or becomes unstable, this indicates that combustion is absent or irregular and that it is necessary to intervene to restore normal combustion conditions.

In modulating burners, as the power is decreased at which the burner is run, the ionisation produced by the flame remains almost constant, or decreases only slightly, until the operating power of the burner reaches a minimum value P_(min), which, in known prior-art burners, is equal to approximately 17-20% of the nominal power of the burner, after which the intensity of ionisation decreases suddenly until it falls below the limit value S_(lim) of sensor sensibility, when the operating power falls below a value P₀<P_(min). The signal S₀ generated by the ionization sensor is also maintained substantially constant or decreases slightly, nevertheless remaining between the values S_(min) and S_(max) until the operating power becomes less than P_(min), after which it falls sharply below the value S_(min) until it is completely cancelled when ionization intensity falls below the sensibility limit of the sensor, when the operating power becomes less than P₀.

It would be theoretically possible to define, for each operating power value between P_(min) and P₀, the value S_(min) and S_(max) within which the signal of the sensor has to be maintained if combustion is regular, but this is complex and difficult to manage.

In known prior-art burners it is not therefore possible to use the ionization sensor to monitor combustion for operating power below P_(min).

The present invention aims to provide a burner that enables the field of use of an ionization sensor to be extended that is associated with a premixed burner, in operating conditions with a power output below 17-20% of the nominal power of the burner down to operating conditions with power output approximately 10% of the nominal power of the burner. According to the present invention a burner is provided comprising a diffuser in which first openings and second openings are made for the passage of a mixture of fuel and air delivered to the burner, a distributing element arranged inside the burner near said diffuser, said distributing element being provided with further first openings and further second openings for the passage of said mixture, an ionization sensor arranged near a zone of the surface of said diffuser in a direction substantially parallel to the surface of the diffuser, characterised in that said further second openings are arranged at said zone of said diffuser, said further second openings having distribution other than the distribution of said further first openings and/or dimensions greater than said further first openings.

The flow of mixture that exits the openings made on the diffuser in the zone near which the ionization sensor is arranged creates combustion conditions that cause ionisation to be kept substantially constant when the operating power of the burner is varied up to approximately 10% of nominal power, so as to enable correct operation of the ionization sensor until said operating power value.

In this way it is possible to extend the adjusting range of the burner beyond the currently possible limits, which entails greater flexibility in the operation of the burner and savings in operating costs.

In an advantageous embodiment of the invention, the diffuser, in the zone adjacent to the ionization sensor has a double row of openings in the shape of slits, that are separated by a surface portion of diffuser devoid of slits, said ionisation probe being arranged parallel to said portion of diffuser devoid of slits.

The arrangement of the slits in the zone of the diffuser near which the ionization sensor is arranged contributes to stabilising ionisation in the zone surrounding the flame.

The invention will now be disclosed, by way of non-limiting example, with reference to the attached tables of drawings, in which:

FIG. 1 is a schematic perspective view of a first embodiment of a burner according to the invention;

FIG. 2 is a raised view of the burner in FIG. 1;

FIG. 3 is section in FIG. 2;

FIG. 4 is an elevation view of a distributing element associated with the burner in FIG. 1;

FIG. 5 is a top view of a second embodiment of a burner according to the invention;

FIG. 6 is section VI-VI of FIG. 5;

FIG. 7 a bottom view of the burner in FIG. 5.

In FIGS. 1 to 4 a first embodiment of a burner 1 according to the invention is illustrated. The burner 1 has a cylindrical shape with a diffuser 2 mounted between an upper base 3 and a lower base 4.

The upper base 3 has a central ridge 5 facing inside the burner. Similarly, the lower base 4 has a central ridge 6, facing inside the burner, in which a central opening 4 a is made for delivering a mixture of air and fuel inside the burner 1.

Between the two ridges 5 and 6 there is mounted and centred a distributing element 7, which is also cylinder-shaped, having a dimension that is less than the diameter of the del diffuser 2, so that a space 8 remains between the external surface of the distributing element 7 and the internal surface of the diffuser 2.

The diffuser 2 is provided with first openings 9 and with second openings 9 a, to enable the mixture to pass from the space 8 to the outside of the burner 1; where combustion of the mixture is brought about.

The first openings 9 take the shape of holes, whilst the second openings 9 a take the shape of slits. Groups of rows of holes 9, arranged parallel to a longitudinal axis of the burner 1 alternate with rows of slits 9 a, which are also arranged parallel to the axis of the burner 1.

Over the entire surface of the diffuser 2 the groups of rows of holes 9 alternate with single rows of slits 9 a, except in a zone A of diffuser in which there are two facing rows 9 b of slits 10 a that are separated by a surface portion B of diffuser devoid of openings.

The distributing element 7 is provided with further first openings 10 and with further second openings 10 a, distributed over the entire surface of the distributing element 7, to enable the passage of the mixture delivered to the burner 1 in said space 8.

The second further openings 10 a of the distributing element 7 are arranged at said zone A of the surface of the diffuser 2, so that the mixture that passes through the second further openings 10 a exits the diffuser 2 through the rows 9 b of slits 9 a.

The second further openings 10 a have a different distribution from the distribution of the further first openings 10 and/or greater dimensions than the dimensions of the further first openings 10. Advantageously, the further second openings 10 a may have a greater distribution density than the distribution density of the further first openings 10. Distribution density is defined as the number of openings per surface unit of the distributing element 7.

At the portion B of diffuser there is arranged, in a direction that is substantially parallel to the surface of the diffuser 2 an ionization sensor 11, represented schematically, in FIG. 2, by a rectilinear segment. The ionization sensor 11 has a first free end and is fixed at a second end to a supporting element 11 a that can be mounted on the burner 1 or also on a wall of a combustion chamber in which the burner 1 is installed.

The number and/or density of the holes 10 a is greater near said second end, whilst it decreases towards said first end. During operation of the burner 1, at the two adjacent rows 9 b of slits a combustion zone is formed in which ionisation is maintained substantially constant when the operating power of the burner varies, up to operating power of approximately 10% of the nominal power of the burner.

This ensures that the ionisation sensor 11 can operate correctly even when the burner operates at very reduced power, down to even approximately 10% the nominal power of the burner, whilst in known prior-art burners the sensor becomes ineffective when power falls below approximately 17-20% of the nominal power of the burner.

In the diagram set out below the signal S₀ generated .by the ionization sensor in a prior-art burner and the signal S′₀ generated by the ionization sensor in a burner according to the invention are compared.

As can be easily seen the signal S′₀ is maintained substantially constant or decreases only slightly up to an operating power value P_(lim) that is noticeably less than the value P_(lim) of a prior-art burner.

Owing to the invention, it is thus possible to obtain a burner modulation range that is wider than that of prior-art burners; which permits greater flexibility in the adjustment of the burner and savings in operating costs.

In FIGS. 5, 6 and 7 there is shown a second embodiment of a burner 1 a according to the invention, in which the diffuser 2 a has a substantially flat surface and consists of a series of diffuser elements 12 that are alongside one another.

With the diffuser 2 a a distributing element 7 a is associated, which also has a substantially flat surface. The distributing element 7 a consists of a series of distributing elements 13 that are alongside one another, each arranged inside a corresponding diffuser element 12. Between each distributing element 13 and the surface of the corresponding diffuser element 12 a space 8 a is defined, in which a mixture of fuel and air is distributed that is delivered to the burner before exiting from the diffuser 2 a.

On the surface of each diffuser element 12 first openings are made consisting of two groups of rows of holes 9, interrupted by a row of second slit-shaped openings 9 a.

In a diffuser element 12 a, on the other hand, two rows of adjacent slits 9 b are made that are separated by a diffuser zone that is devoid of openings.

At said diffuser zone devoid of openings, in a direction substantially parallel to the surface of the diffuser 2 a, an ionization sensor 11 is, arranged that is represented schematically in FIG. 5, with a rectilinear segment. The ionization sensor 11 has a first free end and is fixed at second end to a supporting element 11 a that can be mounted on the burner 1 a or also to a wall of a combustion chamber in which the burner 1 a is installed.

Each distributing element 13 is provided with first further openings 10, in the shape of holes, distributed in a substantially uniform manner on the surface of the distributing element 13. A distributing element 13 a, associated with the diffuser element 12 a, is provided with further second openings 10 a having a different distribution and/or dimensions greater than the first further openings 10. Advantageously, the further second openings 10 a may have a greater distribution density than the distribution density of the further first openings 10.

The second further openings 10 a are distributed in a substantially similar way to the second further openings 10 a of the distributing element 7 of the burner shown in FIGS. 1 to 4 and perform the same function already disclosed previously.

The slits 9 a made in the diffuser 2 of the burner 1 and in the diffuser 2 a of the burner 1 a have, for example, a length comprised between 4 mm and 8 mm and a width comprised between 0.4 mm and 0.8 mm, the length of the slits 9 a is 6 mm, with a width of 0.6 mm.

The holes 9 made in the diffuser 2 of the burner 1 and in the diffuser 2 a of the burner 1 a have a diameter of at least 0.7 mm.

The dimensions of the holes 10 and 10 a made in the diffuser 7 of the burner 1 and in the distributing elements 13 a of the burner 1 a have a diameter comprised between approximately 2.5 mm and 5 mm.

In the practical embodiment, the materials, the dimensions and the constructional details may be different from those indicated without thereby leaving the scope of the invention as defined by the claims. 

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 19. A burner, comprising a diffuser in which first openings and second openings are made for the passage of a mixture of fuel and air delivered to the burner, a distributing element arranged inside the burner near said diffuser, said distributing element being provided with further first openings and further second openings for the passage of said mixture, an ionization sensor arranged near a zone of the surface of said diffuser in a direction substantially parallel to the surface of the diffuser, said first openings having the shape of holes and said second openings having the shape of slits, in said zone two rows of slits being made that are separated by a surface portion of diffuser devoid of openings, wherein said ionization sensor is arranged above said surface portion of diffuser between said two rows of slits.
 20. A burner, as defined in claim 19, wherein said further second openings are arranged at said zone of said diffuser, said further second openings having a distribution other than the distribution of said further first openings and/or dimensions greater than the dimensions of said further first openings.
 21. A burner, as defined in claim 20, wherein said further second openings have a distribution density that is greater than the distribution density of said further first openings.
 22. A burner, as defined in claim 19, wherein said diffuser and said distributing element have a substantially cylindrical shape.
 23. A burner, as defined in claim 21, wherein said diffuser and said distributing element have a substantially flat shape.
 24. A burner, as defined in claim 23, wherein said diffuser comprises a plurality of diffuser elements that are arranged alongside one another.
 25. A burner, as defined in claim 24, wherein said distributing element comprises a plurality of distributing elements each of which is associated with a respective diffuser element.
 26. A burner, as defined in claim 24, wherein said zone comprises one of said diffuser elements.
 27. A burner, as defined in claim 25, wherein each of said distributing elements is provided with said further first openings.
 28. A burner, as defined in claim 27, wherein one of said distributing elements associated with said diffuser element is provided with said further second openings.
 29. A burner, as defined in claim 19, wherein said first hole-shaped openings have a diameter of at least 0.7 mm approximately.
 30. A burner, as defined in claim 19, wherein said second slit-shaped openings have a length comprised between 4 mm and 8 mm and a width comprised between 0.4 mm and 0.8 mm.
 31. A burner, as defined in claim 30, wherein said second slit-shaped openings are 6 mm long and 0.6 mm wide.
 32. A burner, as defined in claim 19, wherein said further first openings and said further second openings have a diameter between approximately 2.5 mm and approximately 5 mm. 